Method for gasifying fuels



METHOD FOR GASIF'YING FUELS Filed Deo. 28, 1945 Edwin. J. GoFzr nvenbo'r lFaq! Clbborneq Patented Mar. 4, 1952 METHOD FOR GASIFYING FUELS Edwin J. Gohr, Summit, N. J., assignor to Standard Oil Development Company, a corporation of Delaware Application December 28, 1945, Serial N o. 637,616

3 Claims. (Cl. 48-206) The present invention relates to the art of producing valuable fuels. More particularly, the present. invention relates to improvements inthe generation of heat and the production of volatile fuels from solid carbonaceous materials, such as coal, coke, peat', tar sands, oil shales, and the like.

It has been long known that solid fuel materials, such as coke, coal, and the like, may be converted into more valuable gaseous fuels which can be more easily handled and more eiciently used. Producer gas, coal gas and water gas processes are well known and widely practiced. However, any of these processes has certain drawbacks. Producer gas has a low heating value, while the production of coal gas or water gas either requires discontinuous operation or involves inefficient conversion of the carbon available into heat or combustible gases. The application of the so-called fluid solids technique to the gasification or carbcnization of solid carbonaceous materials has made the operation fully continuous and brought a number of highly desirable advantages. However, partly as a result of the continuous feed and withdrawal of fresh and spent carbonaceous material to and from a fluidized highly turbulent bed of solids, it is unavoidable that substantial proportions of carbonaceous materials are Withdrawn from the reaction zone before the desired conversion into gaseous fuels is complete. Thus, extensive recycling is required, resulting in an inefficient utilization of reactor space.

It is an important object of my present invention to provide means by which the conversion of solid carbonaceous materials into heat and/or fluid fuels may be accomplished continuously in a iiuidized solids conversion zone and by which the withdrawal of unconverted feed material may be controlled and reduced to any desired level.

I have found that this and other objects and advantages may be accomplished quite generally by restricting the free circulation of fiuidized solids particularly in the direction of the path of the fluidized solids feed through a fiuidized reaction zone and withdrawing solids from a point removed from the solids feed inlet along said path through the reaction zone. In accordance with a preferred embodiment of my invention, I restrict the free circulation of the fluidized solids with the aid of perforated plates orgrids subdividing the reaction zone into sections and restricting solids flow essentially to onedirection from section to section. For example, I may feed solid finely-divided carbonaceous 'material to the top of a verticalelongated reaction zone subdivided by one or more perforated plates into two or more sections in which the solid carbonaceous material is subjected to'the desired reaction in the form of a fluidized mass ofsolids maintained with the aid of fluidi'zing gas injected below one or more of the various perforated plates. The finelydivided solids filter through the reaction zone and may be withdrawn at a point separated by one or more perforated plates from the solids inlet. In this manner, only solids are withdrawn which were subjected tothe desired reaction conditions for the time contemplated. The effect of the plate perforations may be supplemented by suitable overflow connections facilitating the ow of solids from section to section in one direction only.

My invention is equally applicable to the production of fuel gases, such as producer gas or water gas from carbonized fuels, such as coke, by means of steam and to the production of coal gas and other carbonization products by the coking of carbonizable solid fuels, as will appear more clearly hereinafter."

My new process combines the great advantages of the fluid solids technique, such as ease of solids handling, perfect heat distribution throughout the reaction zone and flexibility of operation with a greatly improved utilization of vreactor space, resulting in increased outputs of valuable products per unit of timeand reactor space. These and other advantages will be fully understood from the more detailed description hereinafter, in which reference will be made to the accompanying drawing wherein Fig. 1 is a semi-diagrammatic view in sectional elevation of an apparatus for' carrying out the present process in one conversion zone; and

Fig. 2 is a semi-diagrammatic view in sectional elevation of an apparatusfor carrying out the present process in two separate zones.

Referring now to Fig. l, finely divided carbonaceous solids. such as coke, coal or the like are fed by means of a standpipe, a star or screwfeeder or any other conventional feeding device (not shown) through line I to a vertical substantially cylindrical elongated reaction zene 2 which is subdivided by perforated grids 3 into several sections in whch the solids are maintained in the form of a dense fluidized mass of solids with the aid of gas and/or vapors admitted through lines 5 and/or 'l to the bottom of reactor 2. Thenely-divided solid material may have a particle size of the order'fof below 50 mesh, or even less than 200 mesh, lalthough small lumps up to 1A; or l/2 inch size may be used. If desired, additional gases may be admitted at various points along the height of reactor 2 through lines 9 and/or I I. Good uidization may be achieved at supercial gas velocities ranging from about 0.5 ft. per second to about 10 ft. per` second or higher, depending on the particle size of the solids charged. Volatile products of reaction pass overheadfrom theiluidized massofsolidslinto an enlarged section 100i reactorZ wherein'most of the entrained solids are separated and returned to the reaction zone as a result of the reduced superficial velocity of the gases. VFrom section I the vaporous or gaseous reaction products pass into gas-solids separator I2 which'may be of the electricalfand/or centrifugal type. Solid nes are returned from separator I2 through line I3 to the reaction zone 2whilefvola tile products now substantially free of solids are withdrawn through line I and passed'tofurther processing or product recovery,

Spent solids are v-Wtl'idrawn from-any oneflof the llower f sections, f preferably i the ylowest =1sec ton'off reaction zone V2, through'y lineV I6. -Ifrrdesired, "f overows II 'f may .be arranged between some on all' o'fthe sections' to facilitate the downward of the fluidlzed .i solids. These `:overowpipesk IT-mayibe arranged to cooperate with such"fluidizationrconditions of particle size, solids feed; gas velocity *andi amounts in lreactor f 2 'ras will causethe formation of a `dense '.luidized solidsphase=anda1dilute phase ofisolidsk fines suspended in gases above-each'gridf3 withxwelldefined upper `levelsof thefdense phases Sin each reactor `sectionias-it is indicated iin the drawing. However, the uidization conditions may'alsoV 'be so controlled that the entire reaction zone2ris lled fw-ith Vajuidized` solidspha'se' ofisubstantially uniforrndensity forming only azsingle=well definedl upper level= above thenppermost grid -3 where'the gasesenter therenlarged zone l I8 and the change in superiicial--velocity, causesv a' relatively'steepdrop inthedensity ofthe suspension'. In either case the perforated `grids-3,"whilere stricting-free'vertical circulation of `solids over the'entire'` length of reaction-zone 2,*permit :surncientdownward 'ltration of the solids 'through the vgrid 1 perforations to festablish adeiinite f and continuous fdownward vmovement 'of solids from the uppermost to thelowermostreactor'section. When the particleI size of 'the' solids"feed'arrd"the diameter ofthe grid lperforations are properly correlated, overow'pipes IT Vmay beientirely dispensed with. There may be somecarry-over of solids from lower to upper'sectionscf'the'reaction'vzone caused by '.the counterourrent .gas'slow However, it'will be 4appreciated that the VVsolids withdrawn through line I 6 "cannot contain vany feedl material which i has not Vvbeen subjected to reaction Aconditions 'for' the "intended minimum reaction time which is determinedbythe length of thereaction'zone 2.

yReactor `2 may be used for the production'of coal Igas and volatile carbonization products such as -hydrocarbon oils, ammonia, tar, "tar products 'and coke. For l:this purpose, a carbonizable material,"such as carbonization coal, oilishale, tar sands or the like, is continuously supplied through line` Il and an oxidizing gas,"such asair and/or oxygen, is injecte'd'through line 5 and, l if l desired, throughl one 'or' more ofVV lines 9. 'Thevolumes of oxidizing'gas are carefully controlled-soneto produce justenoughheat by combustion'to supplythat required-for the desired carbonization :of the solid 'carbonaceous material. If desired, an v4auxiliaryinertiiuidiz- 'tire-chargent reactor 2 may be easily maintained at a uniform carbonization temperature-which y*may fall within the range of 10002200 F., prefstituents.

-erably of 12001400 F., to be converted on its path through reactor 2 into volatile carboniza- 'tion productswithdrawn through line I5 and cokeorfcoky residue withdrawn through line I6 in a formsubstantially free of volatilizable con- Ingeneral, this result may be accomplished by supplying about 0.3 cu. ft. to 1.0 cu. it. of oxygen per pound of carbonizable material charged at residence times of solids in the reactor :varying- .from 3.*to 30. minutes.

"When'reactorzZ is-tobe used for the' production of fuelzgases comprising CO and. Ha such '1 as water--gasoiproducer gas, the solid carbonaceous charge which now .zmayinclude coke vor other solid;carbonization'residue Ais supplied toreactor 2,.;'asidescribed above, =and reacted ywith steam supplied through lines 'Ifand/or II. The heat required for the gasication'reaction may be generated by partial'combustion within reactor 2 with the aid of an oxidizing gas, such as air and/oroxygen, supplied' through lines 5 and/or 9 in Aamount-s just suiiicient for the purpose. Steam and oxidizing'gas may either be supplied simultaneously or alternately ina make and blow manner. The combined yeffects lof gasication and combustion cause :substantially complete conversion of the lcarbonaceous charge 'onits path throughzreactor' 2 -into'gaseous fuels withdrawn upwardly through line I5'and ash withdrawn downwardly through-line I6. When the production of water gas substantially free of inert constituents, such as a-feed gas suitableA for the catalytic synthesis of hydrocarbons from CO'and H2v is desired, oxygen or air enriched with oxygen is preferably used as the oxidizing gas. Gasification temperatures may vary between 1400 'and 2400 F. but are preferably kept between about 1600 and 1800D F. Goodresults are generally obtained by supplying 0.5flb. to 3.0 lbs of Ysteam and 'I cu. ft. ito 11'cu.'ft. oxygen per pound of gasiable solids charged at solids'residence times varying between about ,1 i and 5 minutes.

It will vbe understood that both carbonization and gasification 4reactions may vbe operated as fully continuous processes by continuously supplying solid andgaseous reactantsand continuously withdrawing solid and 'gaseous reaction products. If desired, the supply of gaseous reactants'through Ylines 5, "I, 9 and IImay be so controlled Vthat they are vsubstantially vconsumed before'reaching the upperreactor sectionor sections which may in this case serve as preheating zone Vor zones'for the `carbonaceous feed. Obviously, the Vgaseous and/or `solid feed materials may also be `preheated to any desired temperature, particularly for starting purposes. Moreover, the varioussectionsxof reactor 2 maybe arranged in two or more separate yreactors of suitable design and arrangement.

In `accordance with `-another embodiment of my v.invention illustrated in Fig..2^of thedrawingythe'conversion of solid carbonaceous'material into volatilerfuels on the one hand and the generation'of therheatfrequiredfor Athis converarmatore:

Referring now to the production of fuel gases such asl-water gas from solid carbonaceous material-'in the system of Fig. 2, finely-divided carn bonizable solids, such as coke or coal, having a particle size as described above, are fed through line I to an upper or intermediate section of reactor 2 and maintained therein in a fluidized state With the aid of steam and, if desired, other iluidizing gas supplied through line l. Amounts of steam Varying from 0.6 lb. to 2.0 lbs. per pound of solids charged are suflicient for this purpose. The gasification temperatures may vary between about 1400" and 2400o F. and are preferably kept between about 1600 and 1800 F. Heat required for gasification is supplied in the form of sensible heat of solids circulated to reactor 2 from heater 215, as will appear more clearly hereinafter. The carbonaceous solids ltering down through perforated plates 3 and/or overflow pipes I1 are increasingly gasied countercurrent to the steam and fluidizing gas, a gas mixture containing CO and H2 being withdrawn overhead through line I5.

Solid fluidized gasification residue having a carbon concentration of not more than about 2%, preferably less than about 1%, is withdrawn from the lowest and/or an intermediate reactor section through standpipe I6, mixed with an oxidizing gas in line I8 and passed under the pressure of the denser fluidized column in pipe I6, to the bottom portion of heater 25. This heater may be of any conventional design adapted for the combustion of nely-divided solid carbonaceous materials by means of an oxidizing gas, in the form of a dense fluidized mass of solids exhibiting the phenomenon of hindered settling. However, in order to accomplish most eicient combustion and heat generation by substantially complete conversion of reacted carbon to CO2, the combustion is preferablycarried out in at least two successive combustion zones in one of which the feed material of highest carbon concentration is sub- `jected to combustion to form CO2 and CO while in at least one subsequent combustion zone the carbon concentration of the solids is kept low enough to prevent reduction of CO2 formed to CO and to promote substantially complete combustion of CO to CO2 by surface action, if desired, with the aid of added oxidizing gas. To accomplish this effect, heater 25 is shown to consist of an elongated subtantially cylindrical combustion zone subdivided by a member of spaced perforated plates or grids 27 into a number of superimposed combustion sections 28.

In operation, the suspension of solid relatively high-carbon content gasication residue in oxidizing gas enters the lowest combustion section 2S through the lowest distributing grid 21 and combustion to CO and CO2 begins in a dense bed of solids uidized by the oxidizing and combustion gases. As combustion proceeds, solids of decreasing carbon concentration are carried over from section to section to establish therein iluidized beds of decreasing carbon concentration so that the upper sections contain solids containing not more than 1.0%, and preferably less .than 0.2%, of carbon. There may be sui'licient unreacted oxygen left in' the combustion gases to permit complete combustion of CO to CO2 in the upper beds 28 in contact with the hot solids of low carbon content. However, normally it is advisable to supply fresh oxidizing gas through line 30 to one of these upper beds, as will appear more clearly hereinafter. When the carbon content in the upper low-carbon combustion section rises too high as a yresult of carbon carried over from lower high-carbon sections, the effect may be compensated by the addition from lines 32 and 30 of extraneous non-carbonaceous solids, suchas sand, ash, clay or solids catalytically pro- :noting the combustion reaction, such as iron ox-- ide, iron ore, high-iron clays, and the like, or mixtures of these materials. The temperatures within combustion zone 26 may vary between about 1500 and 2500 F., with temperature levels of about 1600-2000 F. in the lower sections of relatively high carbon concentration and about 18002100 F. in the upper sections of relatively low carbon concentration.

Combustion gases consisting essentially of CO2 and unreacted components of the oxidizing gas pass from cylindrical zone 26 into an enlarged section 34 where most of the entrained solids drop out due to the reduced supercial gas velocity. Further suspended fines are separated in conventional gas-solids separator 36 and returned to the combustion zone 26 through line 35.

Fluidized solids oi highest temperature and lowest carbon concentration may be withdrawn through standpipe 38 from the uppermost combustion section 28 of heater 26, and passed substantially at the temperature of this combustion section through line 3Q to one of the upper sections of reactor 2 in amounts suflicient to supply all or part of the heat required therein for gasification. Further amounts of solids contained in pipe 38 may be discarded through line 40. Fluidized solids of equal or slightly higher carbon concentration than withdrawn through line 38 are withdrawn through standpipe 42, preferably from, and substantially at the temperature of, an intermediate combustion section 28. They may be passed through line 44 to a lower section of reactor 2 to supply additional heat required therein. If desired, they may be discarded in part through line d3. It may be desirable to control the temperature of the low-carbon solids at the level desired for heat supply in reactor 2. For this purpose, a portion of the solids in pipe 38 is passed through line Mi, suspended in added uidizing gas, preferably an oxidizing gas, such as air, in line 48 and returned through a heat withdrawal device such as steam boiler or heater 58, and line 3! to'. the uppermost section 28 of heater 25. The steam produced in boiler 50 may be supplied through lines 52 and 1 to reactor 2.

From the foregoing, it will be understood that a system of the type illustrated in Fig. 2 affords a fully continuous process of greatest flexibility and adaptability to raw materials treated and products desired. This embodiment of my invention permits of many modifications. While only a single reactor is shown in Fig. 2, two or more reactors of the type of reactor 2 may be combined with a single heater to carry out simultaneously different reactions such as carbonization and gasification of carbonized solids by suitable circulation of solid feed materials and heatcarrying solids through the system and employing proper types and amounts of gaseous reactants, such as steam and oxidizing gas. In the latter case, it may be desirable to feed carboniza- 7 tion iresidue `from a v'coker Tto 'the .generator and to supply the heat for both carbonization and gas'ication by burning egasic'ation lresidue as outlined above vand feeding hot combustion residue 'to the carbonization and gasification zones in 'suitable proportions. Separate vessels may be provided for each individual section or several combined sections of reactor 2 and heater 25. It

may also be desired to circulate the extraneous ncnca'rbonaceous materials mentioned above at a preferred range of particle size through the system. In that case, these solids withdrawn from the top bed of heater 25 along with ash maybe elu'tria'ted and/or screened to remove the ash fand thenc'e'return'ed to the system for reuse. An oxidizing gas may b'e supplied directly to-reactor T2 to supply additional heat by partial combustion therein, if desired. Also, solid as well als gaseous reactants may be preheated to any fdesired temperature, particularly for the purpose 'of 'starting-up the process.

The system illustrated in Fig. 2 may also be readily adapted to the 'carbonization of distillable carbonaceous materials in reactor 2. For this purpose, finely-divided carbonizable solids are subjected in reactor `2 to carbonization, in countercurrent ilow with carbonization gases and a fluidizing gas, such as steam, supplied through line 1, at temperatures varying between about 800 and 2000 F.,`preferably between about l200 and 12100o F. The heat required for the gasification reaction may be supplied by recirculating hot solids from heater '25 in a manner similar to that described above with reference to the gasication reaction. However, as a result of the largely iixed extremely high carbon content of the carbonization residue withdrawn from reactor 2, the advantage gained by concurrent flow of coke and oxidizing gas and the addition of inert material in the heater is less pronounced than in the case of the gasification reaction which yields residue 'of a rather exiblebut usually very low carbon content. In the case of carbonization, therefore, conventional single-stage fluid heaters may be applied with satisfactory results.

It will be understood that my process can be applied to various operations in which reaction heat is supplied by circulating fluidized solids heated by the combustion of carbonaceous constituents of the circulating solids. My process is of particular advantage when the solids to be used as heat carriers have, prior to the combustion of their carbonaceous constituents, a carbon concentration of not more than about 5%, preferablynot more than about 2%. In general. the initial carbon concentration of the solids subjected to combustion will be chosen the higher the greater the temperature difference between the temperature 'of the solids to be subjected to combustion and 'the desired temperature of the solid Aheat carrier withdrawn "from the combustion zone. lFor instance, in `the conversion of hydrocarbon gases by heat and/or steam .under such conditions that carbonis deposited on the circulating solids, the heat is generated most eiliciently by burning the carbon off the solids in an oxidizing gas in a concurrent manner, as described heretofore, in a heater of the type of vessel 25 in Fig. 2. Other applications as Well, as .for instance ra similar conversion of liquid hydrocarbons, will be apparent.

The :'relativefproportions of solid andigaseous reactants charged and the circulation `rates .of heatscarryingrsolidsin tall .cases .described above may vary within z wide'zlimits, depending ron the l'lli type of materials charged, the reaction desired, and on the desired temperature gradients between heater 25 and reactor 2. For example, good results are obtained in the gasificationto produce CO and H2 when 20-300 lbs. of Vheatcarrying material is circulated per lb. 'of carbonaceous feed, whether solid, liquid, or gaseous. On the other hand, the carbonization of coal, the coking of otherwise useless residual cls,'or the cracking of natural gas, for instance, may be carried out with circulation of 0.5-50 lbs. of hot solids per lb. of carbonaceous feed.

My invention will be further llustratedlby the following specic example of water gas manufacture, using apparatus as shown in Fig. 2. To prepare 1,000,000 cu. ft./day of CO-i-Hz .in about 90% concentration in water gas, 16-20 tons per day of coal ground to about 50% through 50mesh are charged'to generator vessel 2 through line I.

1,000 lbs. per minute of solids from heatervessel 25 are charged to the generator through lines v39 and 44 at an'average temperature of 2000D F., the major portion, say being supplied through line 39. About 1200 lbs/hr. of steam, preheated by exchange with hot water gas from line l5 (in equipment not shown) is introduced through line 1, part of the preheat being supplied, if desired. by cooler 5e via line 52, Temperature resulting in the generator vessel thereby is about 1800" F., whereby about 1,100,000 cu. ft./day of water gas containing about 50% H2 and 40% CO is withdrawn-through line l5. If the Water gas is to be used under sufficient pressure, I find it convenient and economical to maintain, for instance, 50 lbs. per sq. in. gauge pressure on generator 2. Slightly more than 1000 lbs/minute of hot solids containing about 0.6-0.'7% carbon concentration are withdrawn through standpipe I6, suspended in 1000 cu. ft./minute of air introduced by line i8, having been preheated by exchange with flue gas in vequipment not shown, and are 'conducted to the bottomof'heater 25,'which by virtue of its elevation above generator 2 may be held ata pressure of 35-45 lbs. per sq. in. Combustion of the carbonaceous content of the circulating solids reduces the carbon concentration as they progress lupwardly to about 0.2%, and increases the temperature to about 2000 F. at the locations whence heating solids are removed through lines e2 and 38 to supply heat to the generator. Up to 200 lbs. of ash per day, depending on the ash content of the feed and losses in the make and flue gases, are withdrawn through line 4'] to maintain suitable levels in the system, and small amounts, e. g., up to 50 lbs. per minute, of lowcarbon solids are circulated through cooler 50 as necessary to maintain thermal equilibrium in the system, with the aid of up to 10 cu. ft. per minute of 'air introduced through line 48.

While the foregoing description and exemplary operations have served to illustrate specific applications and results of my invention, vother modications obvious to those skilled in the art are within the scope of my invention. 0nly such limitations should be imposed on my invention as are indicated in the appended claims.

I claim:

1. The methodof producing gaseous fuels from solid carbonaceous materials, which comprises maintaining linely `divided solid carbonaceous materials in a verticalfelongated conversionzone in arseries of beds of dense,'ebullient,..fluidized condition by .an upwardly'flowing gas underreaction `conditions suitable .for :the production .of gaseous 'fuels therefrom, feeding inely `divided solid carbonaceous material to the upper portion of said conversion zone, withdrawing fluidized relatively spent low carbon solids from a lower portion of said conversion zone, regulating the free circulation of solids within said luidized beds essentially in a vertical direction downwardly from the upper high carbon portion of said conversion zone to the lower low carbon containing portion of said conversion zone, subjecting the carbonaceous constituents of said withdrawn solids to combustion with a combustionsupporting gas in a vertical elongated combustion zone, maintaining in said combustion zone a plurality of separate superimposed dense, turbulent iluidized solids beds, maintaining a relal tively high carbon concentration in a lower one of said solids beds and a relatively low carbon concentration in a higher one of said solids beds, passing said withdrawn solids to said lower solids bed, supplying said combustion-supporting gas to said lower solids bed to support combustion therein, passing combustion gases and entrained low carbon solids from said lower to said higher solids bed at conditions suitable for converting substantially all of the CO produced to CO2, passing combustion residue from said lower solids bed substantially at the temperature of the latter to said lower portion of said conversion zone and combustion residue from said upper solids bed substantially at the temperature of the latter to said upper portion of said conversion zone to supply heat required in said portions.

2. The process of claim 1 in which said carbonaceous material is carbonizable and said conversion zone is a coking zone.

3. The process of claim 1 in which said first mentioned gas comprises steam and said conversion zone is a gasification zone for the production of H2 and CO.

EDWIN J. GOHR.

REFERENCES CITED The following references are of record in the le of this patent:

UNITED STATES PATENTS Number Name Date 1,687,118 Winkler Oct. 9, 1928 1,898,967 Schneider et al. Feb. 21, 1933 2,379,408 Arveson July 3, 1945 2,425,098 Kassel Aug. 5, 1947 2,433,798 Voorhees Dec. 30, 1947 2,436,938 Scharmann et al. Mar. 2, 1948 2,443,714 Arveson June 22, 1948 2,444,990 Hemminger July 13, 1948 2,445,327 Keith July 20, 1948 2,447,116 Collins Aug. 17, 1948 2,480,670 Peck Aug. 30, 1949 FOREIGN PATENTS Number Country Date 605,027 Germany Nov. 2, 1934 Great Britain Dec. 1, '1922 

1. THE METHOD OF PRODUCING GASEOUS FUELS FROM SOLID CARBONACEOUS MATERIALS, WHICH COMPRISES MAINTAINING FINELY DIVIDED SOLID CARBONACEOUS MATERIALS IN A VERTICAL ELONGATED CONVERSION ZONE IN A SERIES OF BEDS OF DENSE, EBULLIENT, FLUIDIZED CONDITION BY AN UPWARDLY FLOWING GAS UNDER REACTION CONDITIONS SUITABLE FOR THE PRODUCTION OF GASEOUS FUELS THEREFROM, FEEDING FINELY DIVIDED SOLID CARBONACEOUS MATERIAL TO THE UPPER PORTION OF SAID CONVERSION ZONE, WITHDRAWING FLUIDIZED RELATIVELY SPENT LOW CARBON SOLIDS FROM A LOWER PORTION OF SAID CONVERSION ZONE, REGULATING THE FREE CIRCULATION OF SOLIDS WITHIN SAID FLUIDIZED BEDS ESSENTIALLY IN A VERTICAL DIRECTION DOWNWARDLY FROM THE UPPER HIGH CARBON PORTION OF SAID CONVERSION ZONE TO THE LOWER LOW CARBON CONTAINING PORTION OF SAID CONVERSION ZONE, SUBJECTING THE CARBONACEOUS CONSTITUENTS OF SAID WITHDRAWN SOLIDS TO COMBUSTION WITH A COMBUSTIONSUPPORTING GAS IN A VERTICAL ELONGATED COMBUSTION ZONE, MAINTAINING IN SAID COMBUSITION ZONE A PLURALITY OF SEPARATE SUPERIMPOSED DENSE, TURBULENT FLUIDIZED SOLIDS BEDS, MAINTAINING A RELA- 